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Abstract:

A container for transporting glass sheets includes a bottom structure
having a front edge and a back wall and first and second side walls
extending upwardly from the bottom structure. The container also includes
a floor support mechanism coupled to the bottom structure. The floor
support mechanism includes a floor support member extending substantially
horizontally from the back wall a first distance proximate to the front
edge of the bottom structure. The floor support mechanism also includes a
foam rail support member coupled to the floor support member. The foam
rail support member extends substantially horizontally from the back wall
a second distance proximate to the front edge of the bottom structure.
The floor support mechanism further includes a foam rail coupled to the
foam rail support member. The foam rail extends substantially
horizontally from approximately the back wall a third distance that is
less than the second distance.

Claims:

1. A container for transporting glass sheets, said container comprising:
a bottom structure having a front edge; a back wall extending upwardly
from said bottom structure; a first side wall coupled to said back wall
and extending upwardly from said bottom structure; a second side wall
opposite said first side wall coupled to said back wall and extending
upwardly from said bottom structure; a floor support mechanism coupled to
said bottom structure, said floor support mechanism comprising: at least
one floor support member extending substantially horizontally from said
back wall a first distance proximate to said front edge of said bottom
structure; at least one foam rail support member coupled to said at least
one floor support member, wherein said at least one foam rail support
member extends substantially horizontally from said back wall a second
distance proximate to said front edge of said bottom structure; and at
least one foam rail coupled to said at least one foam rail support
member, wherein said at least one foam rail extends substantially
horizontally from approximately said back wall a third distance that is
less than said second distance, wherein said floor support mechanism
facilitates transferring a load exerted by the glass sheets to at least a
portion of said bottom structure.

2. A container for transporting glass sheets in accordance with claim 1,
wherein said second distance at least partially defines a predetermined
distance from said front edge.

3. A container for transporting glass sheets in accordance with claim 1,
wherein said at least one floor support member defines at least one
aperture, wherein said aperture is a predetermined distance from said at
least one foam rail support member.

4. A container for transporting glass sheets in accordance with claim 1,
wherein said at least one floor support member defines at least one first
aperture, at least one second aperture, and a channel therebetween,
wherein said first and second apertures and said channel are configured
to route banding.

5. A container for transporting glass sheets in accordance with claim 4,
wherein: said at least one foam rail comprises two foam rails positioned
on said at least one support member; and said channel comprises two
channels, wherein each of said channels is positioned between said two
foam rails.

6. A container for transporting glass sheets in accordance with claim 1
further comprising a removable front panel coupled to at least a portion
of at least one of said first side wall and said second side wall and
extending therebetween.

7. A container for transporting glass sheets in accordance with claim 1,
wherein said at least one floor support member comprises an oriented
strand board (OSB).

8. A container for transporting glass sheets, said container defining an
internal volume and comprising: a bottom structure; a back wall extending
upwardly from said bottom structure; a first side wall coupled to said
back wall and extending upwardly from said bottom structure; a second
side wall opposite said first side wall coupled to said back wall and
extending upwardly from said bottom structure; and a back support
structure coupled to said back wall and configured to constrain a
plurality of glass sheets, said back support member comprising: at least
one back support member, said at least one back support member extending
in a substantially vertical direction; a first offset member extending
inwardly a first horizontal distance from said at least one back support
member toward the internal volume of said container; a second offset
member positioned below said first offset member and extending inwardly a
second horizontal distance from said at least one back support member
toward the internal volume of said container, wherein the second distance
is greater than the first distance; and at least one foam rail coupled to
a foam rail support member, said foam rail support member is coupled to
said first offset member and said second offset member.

9. A container for transporting glass sheets in accordance with claim 8,
wherein said back wall is substantially vertical and said back support
structure defines a predetermined offset angle with said back wall.

10. A container for transporting glass sheets in accordance with claim 8,
wherein said foam rail support member extends from said bottom structure
to at least one of: a horizontal back support member positioned at an
uppermost portion of said back wall; and a position along said back wall
below said horizontal back support member.

11. A method of assembling a container for transporting glass sheets, the
container defines an internal volume, said method comprising: providing a
bottom structure having a front edge; coupling a back wall to the bottom
structure and extending the back wall upwardly therefrom; coupling a
first side wall to the back wall and extending the first side wall
upwardly from the bottom structure; coupling a second side wall to the
back wall and extending the second side wall upwardly from the bottom
structure, wherein the first and second side walls are opposite to each
other; and assembling a floor support mechanism comprising: coupling at
least one floor support member to the bottom structure, the at least one
floor support member extending substantially horizontally from the back
wall a first distance proximate to the front edge of the bottom
structure; coupling at least one foam rail support member to the at least
one floor support member, wherein the at least one foam rail support
member extends substantially horizontally from the back wall a second
distance proximate to the front edge of the bottom structure; and
coupling a foam rail to the at least one foam rail support member,
wherein the at least one foam rail extends substantially horizontally
from approximately the back wall a third distance that is less than the
second distance.

12. A method in accordance with claim 11, wherein coupling at least one
foam rail support member to the at least one floor support member
comprises positioning at least one foam rail support member a
predetermined distance from the front edge.

13. A method in accordance with claim 11 further comprising forming at
least one aperture within the at least one floor support member, wherein
the at least one aperture is a predetermined distance from the foam rail
support member.

14. A method in accordance with claim 11 further comprising forming at
least one first aperture within the at least one floor support member,
forming at least one second aperture within the at least one floor
support member, and forming a channel therebetween.

15. A method in accordance with claim 14, wherein coupling at least one
foam rail support member to the at least one floor support member
comprises: coupling two foam rails on the at least one floor support
member; and forming two channels between the two foam rails.

16. A method in accordance with claim 15 further comprising coupling a
removable front panel to at least a portion of at least one of the first
side wall and the second side wall and extending therebetween.

17. A method in accordance with claim 11, wherein coupling at least one
floor support member to the bottom structure comprises coupling an
oriented strand board (OSB) to the bottom structure.

18. A method in accordance with claim 11 further comprising: assembling
an inclined back support member comprising: coupling at least one back
support member to the back wall, the at least one back support member
extending in a substantially vertical direction; coupling a first offset
member to the at least one back support member, thereby extending the
first offset member inwardly a first distance from the at least one back
support member toward the internal volume of the container; coupling a
second offset member to the floor support mechanism and below the first
offset member, thereby extending the second offset member inwardly a
second distance from the at least one back support member toward the
internal volume of the container, wherein the second distance is greater
than the first distance; and coupling at least one foam rail support
member to each of the first offset member and the second offset member;
and coupling at least one foam rail to the at least one foam rail support
member.

19. A method in accordance with claim 18, wherein coupling at least one
foam rail support member to each of the first offset member and the
second offset member comprises forming a predetermined offset angle
between the at least one foam rail member and the at least one back
support member.

20. A method in accordance with claim 19, wherein the predetermined
offset angle is approximately five degrees.

Description:

BACKGROUND OF THE INVENTION

[0001] The field of the invention relates generally to a container for
shipping frangible and fragile articles and more particularly, to a
container for transporting a plurality of curved glass sheets, such as
windshields for vehicles.

[0002] Containers for shipping glass or plexiglass sheets, such as
windshields used in automobiles and trucks, are typically corrugated
structures or wood crates (or a combination thereof) supported on a wood
pallet. The containers are preassembled or occasionally shipped in
components to the windshields manufacturer and are set up or assembled
on-site. In at least some known glass shipping containers, bottom support
and side devices include sufficient features to securely support the
glass and withstand the rigors of transportation and be capable of
stacking to maximize warehouse space. This includes providing a snug fit
for the glass. Further, in at least some known glass shipping containers,
the bottom support and side devices are constructed to at least partially
withstand banding pressures from straps or bands utilized in shipping.

[0003] In at least some known cases, shipping the glass sheets in an
upright position increases a propensity for the glass sheets to shift
during transit, thereby stressing the banding and the portions of the
container in contact with the banding. Such increased wear may decrease a
life expectancy of the shipping container, and may allow for some
shifting of the glass sheets resulting in at least some damage to the
glass, as well as the shipping container. Moreover, some glass shipping
containers provide for placing the glass sheets directly on the bottom
pallet, wherein localized induced weight stresses may shorted an expected
lifespan of the shipping container's bottom pallet. Further, the
positioning of banding around the container is often performed in a
haphazard manner because the container does not provide adequate access
for routing the banding when the container is at least partially loaded
with windshields.

BRIEF DESCRIPTION OF THE INVENTION

[0004] In one aspect, a container for transporting glass sheets. The
container includes a bottom structure having a front edge and a back wall
extending upwardly from the bottom structure. The container also includes
a first side wall coupled to the back wall and extending upwardly from
the bottom structure. The container further includes a second side wall
opposite the first side wall coupled to the back wall and extending
upwardly from the bottom structure. The container also includes a floor
support mechanism coupled to the bottom structure. The floor support
mechanism includes at least one floor support member extending
substantially horizontally from the back wall a first distance proximate
to the front edge of the bottom structure. The floor support mechanism
also includes at least one foam rail support member coupled to the at
least one floor support member. The at least one foam rail support member
extends substantially horizontally from the back wall a second distance
proximate to the front edge of the bottom structure. The floor support
mechanism further includes at least one foam rail coupled to the at least
one foam rail support member. The at least one foam rail extends
substantially horizontally from approximately the back wall a third
distance that is less than the second distance. The floor support
mechanism facilitates transferring a load exerted by the glass sheets to
at least a portion of the bottom structure.

[0005] In another aspect, a container for transporting glass sheets is
provided. The container defines an internal volume and includes a bottom
structure and a back wall extending upwardly from the bottom structure.
The container also includes a first side wall coupled to the back wall
and extending upwardly from the bottom structure. The container further
includes a second side wall opposite the first side wall coupled to the
back wall and extending upwardly from the bottom structure. The container
also includes a back support structure coupled to the back wall and
configured to constrain a plurality of glass sheets. The back support
member includes at least one back support member. The at least one back
support member extends in a substantially vertical direction. The back
support member also includes at least one offset member extending
inwardly a distance from the at least one back support member toward the
internal volume of the container. The back support member also includes
at least one foam rail coupled to a foam rail support member. The foam
rail support member is coupled to the at least one offset member.

[0006] In yet another aspect, a method of assembling a container for
transporting glass sheets is provided. The container defines an internal
volume. The method includes providing a bottom structure having a front
edge. The method also includes coupling a back wall to the bottom
structure and extending the back wall upwardly therefrom. The method
further includes coupling a first side wall to the back wall and
extending the first side wall upwardly from the bottom structure. The
method also includes coupling a second side wall to the back wall and
extending the second side wall upwardly from the bottom structure. The
first and second side walls are opposite to each other. The method
further includes assembling a floor support mechanism that includes
coupling at least one floor support member to the bottom structure. The
at least one floor support member extends substantially horizontally from
the back wall a first distance proximate to the front edge of the bottom
structure. The method also includes coupling at least one foam rail
support member to the at least one floor support member. The at least one
foam rail support member extends substantially horizontally from the back
wall a second distance proximate to the front edge of the bottom
structure. The method further includes coupling a foam rail to the at
least one foam rail support member. The at least one foam rail extends
substantially horizontally from approximately the back wall a third
distance that is less than the second distance.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] FIG. 1 is a front view of a glass shipping container according to a
first embodiment of the present invention.

[0008]FIG. 2 is a perspective back view of the glass shipping container
shown in FIG. 1.

[0009]FIG. 3 is a perspective top view of the glass shipping container
shown in FIGS. 1 and 2.

[0010]FIG. 4 is a perspective view of a front panel that is used with the
glass shipping container shown in FIG. 1 and removed therefrom.

[0011]FIG. 5 is a perspective view of a corrugated lip that is used with
the glass shipping container shown in FIG. 3 and taken along area 5.

[0012]FIG. 6 is a perspective view of the corrugated lip shown in FIG. 5
with the front panel shown in FIG. 4 partially removed.

[0013]FIG. 7 is a front view of the glass shipping container shown in
FIG. 1 with the front panel shown in FIG. 4 removed therefrom.

[0014]FIG. 8 is a front view of a back support mechanism that is used
with the glass shipping container shown in FIG. 1.

[0015]FIG. 9 is a perspective side view of the back support mechanism
shown in FIG. 8.

[0016]FIG. 10 is a perspective side view of an alternative back support
mechanism that may be used with the glass shipping container shown in
FIG. 1.

[0017]FIG. 11 is a perspective view of a floor support mechanism that is
used with the glass shipping container shown in FIG. 1.

[0018]FIG. 12 is a front perspective view of the floor support mechanism
shown in FIG. 11.

DETAILED DESCRIPTION OF THE INVENTION

[0019] The following detailed description illustrates the disclosure by
way of example and not by way of limitation. The description clearly
enables one skilled in the art to make and use the disclosure, describes
several embodiments, adaptations, variations, alternatives, and use of
the disclosure, including what is presently believed to be the best mode
of carrying out the disclosure.

[0020] The term "glass sheets" as used herein includes sheets made from
plexiglass, glass, plastic, or other similar frangible or fragile
materials, and/or combinations thereof, which are typically used to make
windshields or other windows for vehicles, or glass sheets for any other
application. While the windshields as alluded to herein are typically
curved, the shipping container described herein may be used with glass
sheets of any configuration and/or orientation.

[0021] The present invention provides a glass shipping container formed
from a plurality of wooden members and corrugated cardboard. The shipping
container includes a bottom, or floor support mechanism that facilitates
supporting the transported glass sheets above a bottom support pallet.
The floor support mechanism also enables banding straps to be routed
around the glass sheets, through holes and grooves formed in an oriented
strand board (OSB) member, and to an outer anchoring portion of the
shipping container, thereby improving the loading and securing the glass
sheets therein. The floor support mechanism is further configured to
strengthen the shipping container while shifting induced weight forces
though the reinforced portions of the OSB member and to a reinforced
portion of the bottom support pallet. The shipping container also
includes an inclined back support mechanism that facilitates stacking
glass sheets within the shipping container such that a substantial
portion of the induced weight forces are transferred to the rear of the
shipping container. The shipping container further includes a top support
member that strengthens the shipping container and reduces the potential
for damage to the glass sheets during transport.

[0022] Referring now to the drawings, and more specifically to FIG. 1,
which is a front view of an example embodiment of a container for
transporting glass sheets, that is, a glass shipping container 100. Glass
shipping container 100 includes a removable front wall, or panel 102.
Front panel 102 includes at least one finger-grip opening 104 for
enabling a user to easily remove front panel 102, thereby improving
access to the interior volume defined therein for loading and unloading
container 100. In the exemplary embodiment, front panel 102 includes a
corrugated cardboard wall 105. Shipping container 100 also includes a
bottom structure, or a bottom support pallet 106 that is manufactured
from a plurality of wood members (not shown) arranged in any
configuration that enables operation of shipping container 100 as
described herein. Support pallet 106 defines a plurality of fork openings
108 that facilitate transport by a fork-type transporting mechanism
including, without limitation, a fork lift truck and a forked hand-cart.
Support pallet 106 and front panel 102 are coupled by standard fastening
mechanisms (not shown) that include, without limitation, screws, bolts,
and nails. Shipping container 100 further includes a plurality of
sidewalls 112, wherein each sidewall 112 includes a front portion (not
shown in FIG. 1) and each sidewall extends vertically upward from support
pallet 106. In the exemplary embodiment, removable front panel 102 and
sidewalls 112 define a first front edge 110 and a second front edge 111,
and cardboard wall 105 extends therebetween. Shipping container 100 is
configured to constrain and protect a plurality of glass sheets (not
shown) during transport.

[0023] In general, in the embodiments described herein, heat-treated soft
wood, that is, southern yellow pine, is used for the wooden components
unless otherwise stated. Alternatively, any wood materials that enable
operation of shipping container 100 as described herein are used.

[0024]FIG. 2 is a perspective back view of glass shipping container 100.
In the exemplary embodiment, glass shipping container 100 includes a back
wall, or panel 120 that extends upward from support pallet 106. In the
exemplary embodiment, back panel 120 includes a corrugated cardboard wall
121. Back panel 120 defines a plurality of banding openings 122 and
support pallet 106 defines at least one banding opening 124. Openings 122
and 124 receive at least one banding 126 therethrough, wherein bandings
126 facilitate securing glass panels (not shown) within shipping
container 100 during transport. Shipping container 100 also includes at
least one banding aperture 128 defined therein, wherein apertures 128
extend from a position near front panel 102 to back panel 120. Apertures
128 facilitate extending banding material (not shown) from front to back
to facilitate securing glass panels therein.

[0025] In the exemplary embodiment, front panel 102 includes an upper
support member 130 and back panel 120 includes an upper support member
132 that is substantially parallel to support member 130, that is,
substantially horizontal. Support members 130 and 132 are fabricated from
substantially unitary 2-inch by 4-inch wood, that is, a 2×4. Also,
in the exemplary embodiment, each of sidewalls 112 includes a support
member 134, wherein both support members 134 are substantially parallel
to each other. Support members 134 are fabricated from substantially
unitary 2-inch by 2.25-inch wood, that is, a 2×21/4 and are coupled
to support members 130 and 132 by standard fastening mechanisms (not
shown) that include, without limitation, screws, bolts, and nails.
Support members 130, 132, and 134 define a substantially open top
arrangement for shipping container 100. Moreover, in the exemplary
embodiment, back panel 120 is coupled to support members 132 and 134 via
a plurality of staples 138. Alternatively, back panel 120 is coupled to
support members 132 and 134 by standard fastening mechanisms (not shown)
that include, without limitation, staples, screws, bolts, and nails.

[0026]FIG. 3 is a perspective top view of glass shipping container 100.
In the exemplary embodiment, glass shipping container 100 includes a
plurality of side panels 140 that are fabricated of corrugated cardboard
and are coupled to support members 132 and 134 via a plurality of staples
138 to form sidewalls 112. Alternatively, each side panel 140 is coupled
to support members 132 and 134 by standard fastening mechanisms (not
shown) that include, without limitation, staples, screws, bolts, and
nails. Side panels 140 are not coupled to support member 130, thereby
facilitating removability features of front panel 102. Front portion 114
of sidewalls 112, each side panel 140, and cardboard wall 105 cooperate
to define a corrugated lip 142 that facilitates holding support member
130 in place when front panel 102 is inserted into shipping container
100. Also, in the exemplary embodiment, glass shipping container 100
includes at least one angled back rest, that is, back support mechanism
144 that facilitates support of glass plates (not shown) in shipping
container 100 during transport.

[0027]FIG. 4 is a perspective view of front panel 102 of glass shipping
container 100 and removed therefrom. This perspective view shows the
interior surface of front panel 102. Front panel 102 includes a plurality
of vertical support members 150 that facilitate stabilizing and
strengthening front panel 102. Support members 150 are made of unitary
wood 2×4s and are coupled to corrugated cardboard wall 105 via any
coupling mechanism that enables operation of shipping container 100 as
described herein including, without limitation, adhesives and staples.

[0028]FIG. 5 is a perspective view of corrugated lip 142 of glass
shipping container 100 taken about area 5 (shown in FIG. 3). FIG. 6 is a
perspective view of corrugated lip 142 with the front panel 102 partially
removed. Front portion 114 of sidewall 112 is folded over to be
substantially perpendicular to side panel 140 and parallel to cardboard
wall 105. In the exemplary embodiment, front portion 114 is coupled to a
front corner vertical support member (not shown in FIGS. 5 and 6) via any
coupling mechanism that enables operation of shipping container 100 as
described herein including, without limitation, adhesives and staples.
Also, in the exemplary embodiment, cardboard wall 105 is coupled to front
portion 114 via any coupling mechanism that enables operation of shipping
container 100 as described herein including, without limitation,
adhesives and staples. Support member 134, side panel 140, front portion
114, cardboard wall 105, and corrugated lip 142 at least partially form a
cavity 154 that receives a portion of front support member 130.

[0029]FIG. 7 is a front view of glass shipping container 100 with front
panel 102 (shown in FIG. 4) removed therefrom. In the exemplary
embodiment, at least one back support mechanism 144 is coupled to back
panel 120, or more specifically, coupled to corrugated cardboard wall 121
and back support member 132 by any means that enables operation of
shipping container 100 as described herein.

[0030] Also, in the exemplary embodiment, glass shipping container 100
includes two back support mechanisms 144. Alternatively, any number of
back support mechanisms 144 is used to enable operation of shipping
container 100 as described herein, including, without limitation, one and
three mechanisms 144. In the exemplary embodiment, each back support
mechanism 144 is an angled backrest that has an approximately five degree
incline (not shown in FIG. 7) that is facilitated by a plurality of
offsets (not shown in FIG. 7, however, described further below). Each
back support mechanism 144 includes a substantially vertical back support
member 160 that is a wooden 2×4. Each member 160 extends from
horizontal back support member 132 to a floor support mechanism 180
(discussed further below). Moreover, each member 160 is coupled to at
least one of corrugated cardboard wall 121, back support member 132,
and/or floor support mechanism 180 by any means that enables operation of
shipping container 100 as described herein.

[0031] Each back support mechanism 144 also includes a foam rail support
member 162 (shown in phantom in FIG. 7) coupled to vertical back support
member 160 by any means that enables operation of shipping container 100
as described herein including, without limitation, fastening hardware and
adhesives. Each foam rail support member 162 is a wooden 1-inch by 4-inch
member, that is, a wooden 1×4 that extends from a predetermined
distance below horizontal back support member 132 to floor support
mechanism 180. Each back support mechanism 144 further includes at least
one foam rail 164 coupled to foam rail support member 162 by any means
that enables operation of shipping container 100 as described herein
including, without limitation, fastening hardware and adhesives. Each
foam rail 164 extends from a predetermined distance below horizontal back
support member 132 to floor support mechanism 180. In the exemplary
embodiment, foam rail 164 and foam rail support member 162 have
substantially similar vertical lengths.

[0032] Further, in the exemplary embodiment, glass shipping container 100
includes a plurality of rear corner vertical support members 170, wherein
each support member 170 is a unitary 2×21/4 wooden member. Each
support member 170 is coupled to corrugated cardboard wall 121 and a side
panel 140 by any means that enables operation of shipping container 100
as described herein including, without limitation, staples and adhesives.
Moreover, shipping container 100 includes a plurality of upper horizontal
side support members 172 and a plurality of lower horizontal side support
members 174. Each of support members 172 and 174 is also a unitary
2×21/4 wooden member that is coupled to a support member 170 by any
means that enables operation of shipping container 100 as described
herein including, without limitation, fastening hardware and adhesives.
Each of members 172 and 174 may be coupled to a side panel 140 by any
means that enables operation of shipping container 100 as described
herein including, without limitation, staples and adhesives. Furthermore,
each upper horizontal side support member 172 is coupled to an adjacent
sidewall support member 134 and each horizontal side support member 174
is coupled to bottom support pallet 106, wherein such coupling is
performed by any means that enables operation of shipping container 100
as described herein including, without limitation, fastening hardware and
adhesives.

[0033] Moreover, in the exemplary embodiment, glass shipping container 100
includes a plurality of front corner vertical support members 176,
wherein each support member 176 is a unitary 2×21/4 wooden member.
Each support member 176 is coupled to one support member 172 and one
support member 174 by any means that enables operation of shipping
container 100 as described herein including, without limitation,
fastening hardware and adhesives. Support members 176 may be coupled to a
side panel 140 and front portion sidewalls 114 by any means that enables
operation of shipping container 100 as described herein including,
without limitation, staples and adhesives.

[0034] Use of unitary 2×21/4 wooden members for support members 170,
172, 174, and 176 facilitate increasing a storage/shipping region within
glass shipping container 100 and access thereto in contrast to standard
wooden 2×4s and 2×3s. Moreover, sidewalls 114 may or may not
include additional support members.

[0035] Also, in the exemplary embodiment, glass shipping container 100
includes floor support mechanism 180. Floor support mechanism 180
includes a floor support member, that is, a horizontal support board 182
that is fabricated from oriented strand board (OSB) material, wherein OSB
material provides sufficient strength and durability for repeated
shipping use with a relatively low cost as compared to other materials,
such as plywood and plastic. Horizontal support board 182 is coupled to
bottom support pallet 106 by any means that enables operation of shipping
container 100 as described herein including, without limitation,
fastening hardware and adhesives. Also, horizontal support board is
substantially laterally centered on pallet 106 and extends approximately
from back panel 120 to front panel 102.

[0036] Floor support mechanism 180 also includes at least one of unitary
1×4 wooden foam rail support member 184 (two shown in phantom in
FIG. 7) that extend approximately from vertical foam rails 164 to
proximately front panel 102. Foam rail support members 184 are coupled to
horizontal support board 182 by any means that enables operation of
shipping container 100 as described herein including, without limitation,
fastening hardware and adhesives. Foam rail support members 184 may also
be coupled to an adjacent vertical support member 162 by any means that
enables operation of shipping container 100 as described herein
including, without limitation, fastening hardware and adhesives.

[0037] Floor support mechanism 180 further includes at least one foam rail
185 that extends proximately from vertical foam rails 164. Foam rail 185
is coupled to a foam rail support member 184 by any means that enables
operation of shipping container 100 as described herein including,
without limitation, fastening hardware and adhesives. Further, in the
exemplary embodiment, glass shipping container 100 includes two rail
support members 184 and two foam rails 185. Alternatively, any number of
support members 184 and rails 185 are used to enable operation of
shipping container 100 as described herein, including, without
limitation, one and three. In the exemplary embodiment, foam rail support
member 182 extends to a point between a front edge (not shown in FIG. 7)
of foam rail 185 and an outer front edge (not shown in FIG. 7) of
horizontal support board 182. Such configuration of support member 182
and foam rail 185 facilitates lifting glass sheets (not shown) away from
horizontal support board 182, thereby facilitating extending a useful
life of board 182 by reducing a potential for wear of board 182 due to
direct contact between the glass sheets and board 182. Moreover, since
the glass sheets rest on foam rails 185, a substantial portion of weight
forces induced by the glass is transferred to the foam, such foam being
easy and inexpensive to replace.

[0038] Floor support mechanism 180 further includes a plurality of banding
guide channels, or grooves 186 that are operatively coupled to a
plurality of banding access apertures, or holes 188, wherein both grooves
186 and holes 188 are defined within horizontal support board 182.
Further, grooves 186 define banding apertures 128, therefore apertures
128 are also defined in horizontal support board 182. Therefore, holes
188 are operatively coupled to apertures 128 via grooves 186, facilitate
channeling banding 126 throughout the bottom portion of glass shipping
container 100, thereby facilitating support of glass sheets (not shown)
therein throughout transit. One embodiment of shipping container 100
includes two holes 188 for each groove 186, wherein each grove is inboard
from, and adjacent to, a foam rail 184. An alternative embodiment of
shipping container 100 includes three holes 192 for a single groove 190,
wherein both holes 192 and groove 190 are aligned about an approximate
center of horizontal support board 182. Further, alternatively, any
number of holes 188 and 192 and any number of grooves 186 and 190 are
formed within horizontal support board 182 that enables operation of
shipping container 100 as described herein.

[0039]FIG. 8 is a front view of back support mechanism 144 that is used
with glass shipping container 100 (shown in FIG. 1). FIG. 9 is a
perspective side view of back support mechanism 144. In the exemplary
embodiment, back support mechanism 144 includes a first offset member 202
extending a first offset distance 204 from vertical back support member
160 into the interior volume of shipping container 100. First offset
member 202 is coupled to vertical back support member 160 by any means
that enables operation of shipping container 100 as described herein
including, without limitation, fastening hardware and adhesives,
proximate to a top of foam rail support members 162 and foam rails 164.

[0040] Back support mechanism 144 also includes a second offset member 206
extending a second offset distance 208 from vertical back support member
160 into the interior volume of shipping container 100. Offset member 206
rests upon and is coupled to horizontal support board 182 by any means
that enables operation of shipping container 100 as described herein
including, without limitation, fastening hardware and adhesives. Also,
offset member 206 rests against vertical back support member 160 such
that offset member 206 is coupled to vertical back support member 160 by
a pressure, or friction fit. Alternatively, offset member 206 is coupled
to vertical back support member by any means that enables operation of
shipping container 100 as described herein including, without limitation,
fastening hardware and adhesives. Second distance 208 is greater than
first distance 204, thereby defining an offset angle 210 with respect to
vertical. In the exemplary embodiment, offset angle 210 has a value of
approximately five degrees. Alternatively, offset angle 210 has any value
that enables operation of shipping container 100 as described herein.
Foam rail support member 162 is coupled to each of first and second
offset members 202 and 206, respectively, as shown by arrow 212 and foam
rail 164 is coupled to support member 162 as shown by arrow 214, thereby
inclining foam rail support member 162 and foam rail 164 by offset angle
210. Inclined back support mechanism 144 facilitates stacking glass
sheets (not shown) within shipping container 100 such that a substantial
portion of induced weight forces are transferred to a rearward portion of
shipping container 100.

[0041] In the exemplary embodiment, offset members 202 and 206 are unitary
wooden members. Alternatively, offset members 202 and 206 have any
configuration that enables operation of shipping container 100 as
described herein including, without limitation, at least one portion of a
2×4 or a plurality of portions of 2×4 coupled together.

[0042]FIG. 10 is a perspective side view of an alternative back support
mechanism 209 that may be used with glass shipping container 100 (in FIG.
1). In this exemplary alternative embodiment, a single back support
mechanism 209 is coupled to back panel 120 (shown in FIG. 7), or more
specifically, coupled to at least one of corrugated cardboard wall 121
and back support member 132 by any means that enables operation of
shipping container 100 as described herein. Alternatively, any number of
back support mechanisms 209 is used to enable operation of shipping
container 100 as described herein, including, without limitation, two and
three mechanisms 209. In the exemplary embodiment, each back support
mechanism 209 is an angled backrest that has an approximately five degree
incline 210 that is facilitated by a single offset member 206. Each back
support mechanism 209 also includes a foam rail support member 211
coupled to at least one of corrugated cardboard wall 121, back support
member 132, and/or floor support mechanism 180 by any means that enables
operation of shipping container 100 as described herein. Each foam rail
support member 211 is a wooden 2-inch by 6-inch member, that is, a wooden
2×6 that extends from horizontal back support member 132 to floor
support mechanism 180. Each back support mechanism 209 further includes
at least one foam rail 215 coupled to foam rail support member 211 as
shown by arrow 213 by any means that enables operation of shipping
container 100 as described herein including, without limitation,
fastening hardware and adhesives. Each foam rail 215 extends from a
predetermined distance below horizontal back support member 132 to floor
support mechanism 180.

[0043]FIG. 11 is a perspective view of floor support mechanism 180 that
is used with glass shipping container 100 (shown in FIG. 1). FIG. 12 is a
front perspective view of floor support mechanism 180. In the exemplary
embodiment, both horizontal support board 182 and bottom support pallet
106 have a first length L1 that defines a first distance D1
from back panel 120 to an outer front edge 218 of bottom support pallet
106. Also, in the exemplary embodiment, foam rail support member 184 has
a second length L2 that defines a second distance D2 from back
panel 120 and foam rail support member 184 includes an outer edge 216
that is proximate to outer front edge 218. Edges 216 and 218 and
distances D1 and D2 define a distance 220 therebetween.
Moreover, foam rail 186 has a third length L3 that defines a third
distance D3 from back panel 120 and foam rail 186 includes an outer
edge 222 that defines a distance 224 between edges 222 and 216 and
D2 and D3. Distance 224 facilitates shifting induced weight
forces from substantially transferring to horizontal support board 182 to
transferring to a more robust portion of bottom support pallet 106 within
distance 224. Furthermore, such stresses are shifted away from a portion
of OSB horizontal support board 182 in the vicinity of banding guide
holes 188, wherein an ability to withstand such stresses may be
diminished, that is, a predetermined distance 226 between a front-most
hole 188 and edge 216 of foam rail support member 184. Distances 220,
224, and 226 have any values that enable operation of shipping container
100 as described herein.

[0044] The above-described container provides a glass shipping container
formed from a plurality of wooden members and corrugated cardboard. More
specifically, the shipping container as described herein includes a
bottom, or floor support mechanism that facilitates supporting the
transported glass sheets above a bottom support pallet. Also, the floor
support mechanism enables banding straps to be routed around the glass
sheets, through holes and grooves formed in an oriented strand board
(OSB) member, and to an outer anchoring portion of the shipping
container, thereby improving the loading and securing the glass sheets
therein. Further, specifically, the floor support mechanism is configured
to strengthen the shipping container while shifting induced weight forces
though the reinforced portions of the OSB member and to a reinforced
portion of the bottom support pallet. Moreover, the shipping container as
described herein includes an inclined back support mechanism that
facilitates stacking glass sheets within the shipping container such that
a substantial portion of the induced weight forces are transferred to the
rear of the shipping container. The shipping container as described
herein further includes a top support member that strengthens the
shipping container and reduces the potential for damage t the glass
sheets during transport.

[0045] Exemplary embodiments of a container formed to contain glass sheets
therein are described above in detail. The container is not limited to
the specific embodiments described herein, but rather, components of the
container may be utilized independently and separately from other
components described herein. For example, the container features may also
be used in combination with other types of containers, and is not limited
to practice with only rectangular containers, as described herein.
Rather, the exemplary embodiment can be implemented and utilized in
connection with many other container applications.

[0046] Although specific features of various embodiments of the invention
may be shown in some drawings and not in others, this is for convenience
only. In accordance with the principles of the invention, any feature of
a drawing may be referenced and/or claimed in combination with any
feature of any other drawing.

[0047] This written description uses examples to disclose the invention,
including the best mode, and also to enable any person skilled in the art
to practice the invention, including making and using any devices or
systems and performing any incorporated methods. The patentable scope of
the invention is defined by the claims, and may include other examples
that occur to those skilled in the art. Such other examples are intended
to be within the scope of the claims if they have structural elements
that do not differ from the literal language of the claims, or if they
include equivalent structural elements with insubstantial differences
from the literal language of the claims.